Design Process:

• Conceptual design based on design requirements and existing market options

• Basic geometry modelled in SolidWorks CAD

• Load determination conducted in accordance with ASME BTH-1 and CSA S16

  • Load cases included standard lifting conditions, maximum tool misalignment, and maximum environmental loading (wind, snow, etc)

• Key structural components sized in accordance with hand calculations and load determination

• Detailed design

Finite Element Analysis:

• Due to the component geometry exceeding reasonable hand calculation complexity, a 185-body SolidWorks FEA study was undertaken

• Due to the study consisting of many thin-walled structural members and plates, a shell study was conducted to increase model accuracy and improve run time

• 3 different load cases were run, with unique fixturing and loading in each

• Study results were analyzed in conjunction with ASME BTH-1 standards, including utilizing a safety factor of 2 on final FEA stress and deflection values

• Iterative design occurred in response to simulation results, dissipating regions of high stress and stiffening regions of large displacement

Manufacturing Considerations:

• DFM (specifically welding)

• Ensured adequate space for weld torch access, as well as creating a manufacturable sequence to assemble pieces of the weldment

• Created engineering shop drawings for fabrication

This project deepened my technical understanding more than any other. The exposure to code-based design, calculations, and an extensive FEA simulation deepened my practical knowledge. While leading communication with critical foreign suppliers, project managers, and upper management gave me opportunities to champion this project and have full ownership throughout the design process.